Footwear Assembly Method With 3D Printing

ABSTRACT

Methods and systems are disclosed for apparel assembly using three-dimensional printing directly onto fabric apparel materials. Disclosed is a method and system for direct three-dimensional printing and assembly of an article of apparel, including designing a three-dimensional pattern for printing, positioning at least a portion of the article on a tray in a three-dimensional printing system, the portion being positioned substantially flat on the tray, printing a three-dimensional material directly onto the article using the designed pattern, curing the printed material, and removing the article from the three-dimensional printing system.

TECHNICAL FIELD

This disclosure relates generally to the field of three-dimensional(“3D”) printing onto an article of apparel, footwear, or equipment, andmore specifically to methods and systems for apparel assembly using 3Dprinting directly onto fabric apparel materials.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate embodiments and, together withthe description, serve to explain the features, advantages, andprinciples of the embodiments disclosed throughout this disclosure. Forillustration purposes, the following drawings may not be to scale.Moreover, like reference numerals designate corresponding partsthroughout the different views. In the drawings:

FIG. 1 shows an elevated view of an article of footwear consistent withan embodiment of the disclosure;

FIG. 2 shows an elevated view of a top portion of an article of footwearconsistent with an embodiment of the disclosure;

FIG. 3 shows an elevated view of a medial side of an article of footwearconsistent with an embodiment of the disclosure;

FIG. 4 shows a perspective cutaway view of an article of footwearconsistent with an embodiment of the disclosure;

FIG. 5 shows an exploded perspective cutaway view of an article offootwear consistent with an embodiment of the disclosure;

FIG. 6 shows a schematic view of a 3D printing system consistent with anembodiment of the disclosure;

FIG. 7 shows a perspective view of a 3D printer with an upper portion ofan article of footwear inserted therein, consistent with an embodimentof the disclosure;

FIG. 8 shows a cross sectional view of a conventional 3D printed surfaceon a release layer over a substrate;

FIG. 9 shows a cross sectional view of a conventional 3D printed surfacebeing removed from a release layer and substrate;

FIG. 10 shows a cross sectional view of a 3D printed material on anupper portion of an article of footwear, consistent with an embodimentof the disclosure;

FIG. 11 shows a cross sectional view of a 3D printed material on anupper portion of an article of footwear being removed from a tray,consistent with an embodiment of the disclosure;

FIG. 12 shows a perspective view of a 3D printed material on an upperportion of an article of footwear, consistent with an embodiment of thedisclosure;

FIG. 13 shows a perspective view of a 3D printed material on an upperportion of an article of footwear being removed from a tray, consistentwith an embodiment of the disclosure;

FIG. 14 shows a cross sectional view of a first layer of 3D printedmaterial on an upper portion of an article of footwear and a curingprocess, consistent with an embodiment of the disclosure;

FIG. 15 shows a cross sectional view of a second layer of 3D printedmaterial on an upper portion of an article of footwear and a curingprocess, consistent with an embodiment of the disclosure;

FIG. 16 shows a cross sectional view of a third layer of 3D printedmaterial on an upper portion of an article of footwear and a curingprocess, consistent with an embodiment of the disclosure;

FIG. 17 shows a cross sectional view of a fourth layer of 3D printedmaterial on an upper portion of an article of footwear and a curingprocess, consistent with an embodiment of the disclosure;

FIG. 18 shows an overhead view of an upper portion of an article offootwear placed on a tray and prior to 3D printing, consistent with anembodiment of the disclosure;

FIG. 19 shows a cross sectional view of part of the upper portion of anarticle of footwear shown in FIG. 18 placed on a tray and prior to 3Dprinting, consistent with an embodiment of the disclosure;

FIG. 20 shows an overhead view of an upper portion of an article offootwear placed on a tray and post 3D printing, consistent with anembodiment of the disclosure;

FIG. 21 shows a cross sectional view of part of the upper portion of anarticle of footwear shown in FIG. 20 placed on a tray and post 3Dprinting, consistent with an embodiment of the disclosure;

FIG. 22 shows an elevated view of an article of footwear after printingof the 3D sole structure on a bottom surface of the upper, consistentwith an embodiment of the disclosure;

FIG. 23 shows a schematic view of a 3D printing system and methodconsistent with an embodiment of the disclosure;

FIG. 24 shows a process for manufacturing an article of footwear,consistent with an embodiment of the disclosure;

FIG. 25 shows a first part of the process shown in FIG. 24 formanufacturing an article of footwear, consistent with an embodiment ofthe disclosure;

FIG. 26 shows a second part of the process shown in FIG. 24 formanufacturing an article of footwear, consistent with an embodiment ofthe disclosure;

FIG. 27 shows an overhead view of an upper portion of an article offootwear after printing and prior to completion of footwear assemblyconsistent with an embodiment of the disclosure;

FIG. 28 shows a perspective view of an upper portion of an article offootwear after printing and during formation into a secondary shapeconsistent with an embodiment of the disclosure;

FIG. 29 shows a perspective view of an upper portion of an article offootwear after formation into a secondary shape consistent with anembodiment of the disclosure;

FIG. 30 shows a perspective view of an upper portion of an article offootwear after printing and during formation into a secondary shapeconsistent with an embodiment of the disclosure;

FIG. 31 shows a perspective view of an upper portion of an article offootwear after formation into a secondary shape consistent with anembodiment of the disclosure;

FIG. 32 shows a perspective view of a bottom portion of an upper portionof an article of footwear after formation into a secondary shape andduring preparation for additional printing consistent with an embodimentof the disclosure;

FIG. 33 shows a perspective view of a bottom portion of an upper portionof an article of footwear after formation into a secondary shape andduring preparation for additional printing consistent with an embodimentof the disclosure;

FIG. 34 shows a cross sectional view of a first layer of 3D printedmaterial on a sole portion of an article of footwear and a curingprocess, consistent with an embodiment of the disclosure;

FIG. 35 shows a cross sectional view of a second layer of 3D printedmaterial on a sole portion of an article of footwear and a curingprocess, consistent with an embodiment of the disclosure;

FIG. 36 shows a cross sectional view of a third layer of 3D printedmaterial on a sole portion of an article of footwear and a curingprocess, consistent with an embodiment of the disclosure;

FIG. 37 shows a cross sectional view of a fourth layer of 3D printedmaterial on a sole portion of an article of footwear and a curingprocess, consistent with an embodiment of the disclosure;

FIG. 38 shows a perspective view of a sole portion of an article offootwear after 3D printing consistent with an embodiment of thedisclosure;

FIG. 39 shows a perspective view of an exemplary sole portion of anarticle of footwear after 3D printing onto an upper portion consistentwith an embodiment of the disclosure;

FIG. 40 shows a perspective view of an upper portion of an article offootwear after 3D printing, consistent with an embodiment of thedisclosure;

FIG. 41 shows an elevated view of a completed article of footwear after3D printing of the sole portion and upper portion, consistent with anembodiment of the disclosure;

FIG. 42 shows an elevated view of a top portion of the article offootwear shown in FIG. 41, consistent with an embodiment of thedisclosure;

FIG. 43 shows an elevated view of a medial side of the article offootwear shown in FIG. 41, consistent with an embodiment of thedisclosure;

FIG. 44 shows an elevated view of a rear portion of the article offootwear shown in FIG. 41, consistent with an embodiment of thedisclosure; and

FIG. 45 shows and elevated view of a bottom portion of the article offootwear shown in FIG. 41, consistent with an embodiment of thedisclosure.

DETAILED DESCRIPTION

The following discussion and accompanying figures disclose methods andsystems for 3D printing and assembly of an article of footwear having anupper that includes 3D printing directly onto at least a first portionof an upper material and a sole formed by 3D printing onto at least asecond portion of the upper material. In particular, an exemplary methodis disclosed for 3D printing directly onto a fabric material, whichallows building of a structure on the fabric for use in apparelapplications. The disclosed methods and systems may use any suitable 3Dprinting system.

As used throughout this disclosure, the terms “three-dimensionalprinting system,” “three-dimensional printer,” “3D printing system,” and“3D printer” refer to any known 3D printing system or printer. Contraryto known 3D printing methods, however, the disclosed methods and systemsaccomplish 3D printing directly onto any surface of a textile, a naturalfabric, a synthetic fabric, a knit, a woven material, a nonwovenmaterial, a mesh, a leather, a synthetic leather, a polymer, a rubber,and a foam, or any combination of them, without the need for a releaselayer interposed between a substrate and the bottom of the printedmaterial, and without the need for a perfectly or near-perfectly flatsubstrate surface on which to print. For example, the disclosed methodsmay include printing a resin, acrylic, or ink material onto a fabric,for example a knit material, where the material is adhered/bonded to thefabric and where the material does not generally delaminate when flexed,rolled, worked, or subject to additional assembly processes/steps. Asused throughout this disclosure, the term “fabric” may be used to refergenerally to materials chosen from any textile, natural fabric,synthetic fabric, knit, woven material, nonwoven material, mesh,leather, synthetic leather, polymers, rubbers, and foam. Also as usedthroughout this disclosure, the terms “printing” or “printed,” and“depositing” or “deposited,” are each used synonymously, and areintended to refer to the association of a material from a source of thematerial to a receiving surface or object.

Consistent with an embodiment, an exemplary article of footwear isdisclosed as having a general configuration suitable for walking orrunning. As used throughout this disclosure, the terms “article offootwear” and “footwear” include any footwear and any materialsassociated with footwear, including an upper, and may also be applied toa variety of athletic footwear types, including baseball shoes,basketball shoes, cross-training shoes, cycling shoes, football shoes,tennis shoes, soccer shoes, and hiking boots, for example. As usedthroughout this disclosure, the terms “article of footwear” and“footwear” also include footwear types that are generally considered tobe nonathletic, formal, or decorative, including dress shoes, loafers,sandals, slippers, boat shoes, and work boots. Disclosed embodimentsapply, therefore, to any footwear type.

While the disclosed embodiments are described in the context offootwear, the disclosed embodiments may further be equally applied toany article of clothing, apparel, or equipment that includes 3Dprinting. For example, the disclosed embodiments may be applied hats,caps, shirts, jerseys, jackets, socks, shorts, pants, undergarments,athletic support garments, gloves, wrist/arm bands, sleeves, headbands,any knit material, any woven material, any nonwoven material, sportsequipment, etc. Thus, as used throughout this disclosure, the term“article of apparel” may refer to any apparel or clothing, including anyarticle of footwear, as well as hats, caps, shirts, jerseys, jackets,socks, shorts, pants, undergarments, athletic support garments, gloves,wrist/arm bands, sleeves, headbands, any knit material, any wovenmaterial, any nonwoven material, etc. As used throughout thisdisclosure, the terms “article of apparel,” “apparel,” “article offootwear,” and “footwear” may also refer to a textile, a natural fabric,a synthetic fabric, a knit, a woven material, a nonwoven material, amesh, a leather, a synthetic leather, a polymer, a rubber, and a foam.For example, materials used in footwear formation are disclosed in U.S.Pat. No. 5,709,954, which is incorporated by reference.

In accordance with the systems and methods described throughout thisdisclosure, there is provided a method of three-dimensional printing andassembly of an article of apparel, comprising: designing at least onefirst three-dimensional pattern and at least one secondthree-dimensional pattern for printing onto the article; positioning afirst portion of the article on a tray in a three dimensional printingsystem, the first portion being positioned substantially flat on thetray; printing at least one first three-dimensional material directlyonto the first portion of the article using the designed at least onefirst three-dimensional pattern; curing the at least one firstthree-dimensional printed material; positioning a second portion of thearticle on the tray, the second portion being positioned substantiallyflat on the tray; printing at least one second three-dimensionalmaterial directly onto the second portion of the article using thedesigned at least one second three dimensional pattern; curing the atleast one second three-dimensional printed material; and removing thearticle from the three-dimensional printing system.

In accordance with the systems and methods described throughout thisdisclosure, there is also provided a method of fabricating an article offootwear, comprising: designing at least one first three-dimensionalpattern for printing onto an upper and at least one secondthree-dimensional pattern for printing a sole; providing the at leastone first three-dimensional pattern and the at least one secondthree-dimensional pattern to a print server; positioning at least afirst portion of the upper on a tray in a three dimensional printingsystem, the first portion of the upper being positioned substantiallyflat on the tray; aligning the first portion of the upper on the traywith the at least one first three dimensional pattern; printing at leastone first three-dimensional material directly onto the first portion ofthe upper using the designed at least one first three-dimensionalpattern on the print server and the three-dimensional printing system;curing the at least one first three-dimensional printed material;removing the upper from the three-dimensional printing system; formingthe upper into a secondary shape; placing the formed upper on a holder;positioning the holder on the tray, the holder being positioned on thetray to present a sole surface portion of the formed upper for printingthe sole; aligning the holder on the tray with the at least one secondthree dimensional pattern; printing the sole with at least one secondthree-dimensional material directly onto the sole surface portion of theformed upper using the designed at least one second three dimensionalpattern on the print server and the three-dimensional printing system;curing the at least one second three-dimensional printed material;removing the holder from the three-dimensional printing system; andremoving the fabricated article of footwear from the holder.

In accordance with the systems and methods described throughout thisdisclosure, there is provided a system for three-dimensional printingdirectly onto multiple surfaces of a fabric material, comprising: afirst nontransitory computer-readable medium encoded with a firstcomputer program product loadable into a first memory of a firstcomputer and including first software code portions for storing athree-dimensional pattern for printing directly onto the upper; a printserver; a switching device; and a three-dimensional printer device,wherein the print server is in direct communication with the threedimensional printer device and the switching device, wherein theswitching device is in direct communication with the three dimensionalprinter device and the print server, wherein the first nontransitorycomputer readable medium is in direct communication with the switch,wherein the print server comprises a second nontransitorycomputer-readable medium encoded with a second computer program productloadable into a second memory of a second computer and including secondsoftware code portions for instructing the three-dimensional printingdevice to print directly onto the upper through a first sequence ofprinting steps and a second sequence of printing steps; wherein thethree dimensional printer device comprises a tray receiving at least afirst surface of the fabric material and at least a second surface ofthe fabric material, at least one printing head for printing onto afirst portion of the upper in the first sequence and onto a secondportion of the upper in the second sequence, and at least oneultraviolet light for curing material printed onto the upper in thefirst and second sequences, and wherein the three dimensional printingsystem does not require a substantially flat surface for printing.

Additional features and advantages will be set forth in part in thedescription that follows, being apparent from the description or learnedby practice of embodiments. Both the foregoing description and thefollowing description are exemplary and explanatory, and are intended toprovide further explanation of the embodiments as claimed.

An article of footwear generally includes two primary elements: an upperand a sole structure. The upper may be formed from a plurality ofmaterial elements (e.g., one or more layers of a textile, a naturalfabric, a synthetic fabric, a knit, a woven material, a nonwovenmaterial, a mesh, a leather, a synthetic leather, a polymer, a rubber,and a foam, etc.) stitched or adhesively bonded together to form a voidon the interior of the footwear for comfortably and securely receiving afoot. More particularly, the upper forms a structure that extends overinstep and toe areas of the foot, along medial and lateral sides of thefoot, and around a heel area of the foot. The upper may also incorporatea lacing system to adjust fit of the footwear, as well as permittingentry and removal of the foot from the void within the upper. Inaddition, the upper may include a tongue that extends under the lacingsystem to enhance adjustability and comfort of the footwear, and theupper may incorporate a heel counter. For example, the upper may be ahigh tensile strength knit or mesh sockfit upper.

Various material elements forming the upper may impart differentproperties to different areas of the upper. For example, textileelements may provide breathability and may absorb moisture from thefoot, foam layers may compress to impart comfort, and leather may impartdurability and wear-resistance. Consistent with an embodiment,therefore, 3D printed materials disposed on the upper during assembly ofan article of footwear may thus be used to customize the properties ofthe upper and hence article of footwear. As disclosed throughout thisdisclosure, for example, 3D printed materials may be disposed on theupper to impart customized material properties such as increasedstrength, rigidity, support, flexibility, abrasion resistance, orvariations thereof, based on desired material properties for specificportions of the upper and the article of footwear as a whole.

A sole structure is secured to a lower portion of the upper so as to bepositioned between the foot and the ground. In athletic footwear, forexample, the sole structure includes a midsole and an outsole. Themidsole may be formed from a polymer foam material that attenuatesground reaction forces (i.e., provides cushioning) during walking,running, and other ambulatory activities. The midsole may also includecushions, such as fluid-filled chambers, plates, moderators, or otherelements that further attenuate forces, enhance stability, or influencethe motions of the foot, for example. The outsole forms aground-contacting element of the footwear and is usually fashioned froma durable and wear-resistant rubber material that includes texturing toimpart traction. The sole structure may also include a socklinerpositioned within the upper and proximal to a lower surface of the footto enhance footwear comfort.

Consistent with an embodiment, an article of footwear 10, throughoutthis disclosure referred to simply as footwear 10, is depicted in FIGS.1-3 as including an upper 20 and a sole structure 30. For referencepurposes, footwear 10 may be divided into three general regions: aforefoot region 11, a midfoot region 12, and a heel region 13. Footwear10 also includes a lateral side 14 and a medial side 15. Forefoot region11 generally includes portions of footwear 10 corresponding with thetoes and the joints connecting the metatarsals with the phalanges.Midfoot region 12 generally includes portions of footwear 10corresponding with the arch area of the foot, and heel region 13corresponds with rear portions of the foot, including the calcaneusbone. Lateral side 14 and medial side 15 extend through each of forefootregion 11, midfoot region 12, and heel region 13 (as seen in FIG. 3) andcorrespond with opposite sides of footwear 10 that are separated by alace region 16, which extends along a length of footwear 10. Forefootregion 11, midfoot region 12, heel region 13, lateral side 14, andmedial side 15 are not intended to demarcate precise areas of footwear10. Rather, they are intended to represent general areas of footwear 10to aid in this description. In addition to footwear 10, forefoot region11, midfoot region 12, heel region 13, lateral side 14, and medial side15 may also be applied to upper 20, sole structure 30, and individualelements thereof.

Consistent with an embodiment, sole structure 30 is printed directlyonto upper 20 and extends between the foot and the ground when footwear10 is worn. The primary elements of sole structure 30 are a midsole 31,and one or more outsole regions 32. Footwear 10 optionally includes asockliner 33, which may be part of upper 20. A lower surface of upper 20is secured to midsole 31, and midsole 31 may be formed from a printedand compressible polymer foam element (e.g., a polyurethane orethylvinylacetate foam) that attenuates ground reaction forces (i.e.,provides cushioning) when compressed between the foot and the groundduring walking, running, or other ambulatory activities. In furtherconfigurations, printed midsole 31 may incorporate fluid-filledchambers, plates, moderators, or other elements that further attenuateforces, enhance stability, or influence the motions of the foot, orprinted midsole 31 may be primarily formed from a fluid-filled chamber.Outsole 32 is also printed onto a lower surface of midsole 31 and may beprinted to form a wear-resistant material (e.g., a polymer or a rubber)that is textured to impart traction and provide durability. Althoughthis configuration for sole structure 30 provides an example of a solestructure that may be used in connection with upper 20, a variety ofother conventional or nonconventional configurations for sole structure30 may also be utilized. Accordingly, the structure and features of solestructure 30 or any sole structure utilized with upper 20 may varyconsiderably.

Upper 20 may be stitched or bonded together to form a void withinfootwear 10 for receiving and securing a foot relative to sole structure30. The void is shaped to accommodate the foot and extends along thelateral side of the foot, along the medial side of the foot, over thefoot, around the heel, and under the foot. Access to the void isprovided by an ankle opening 50 located in at least heel region 13.

Lace 40 may extend through various lace apertures 41 and permits thewearer to modify dimensions of upper 20 to accommodate the proportionsof the foot. More particularly, lace 40 may permit the wearer to tightenupper 20 around the foot, and lace 40 may permit the wearer to loosenupper 20 to facilitate entry and removal of the foot from the void(i.e., through ankle opening 50). As an alternative to lace apertures41, upper 20 may include other lace-receiving elements, such as loops,eyelets, and D-rings. In addition, upper 20 may include a tongue 60 thatextends between ankle opening 50 and lace 40 to enhance the comfort andperformance of footwear 10. In some configurations, upper 20 mayincorporate a heel counter that limits heel movement in heel region 13or a wear-resistant toe guard located in forefoot region 11. In somecases, upper 20 may include a plurality of lace apertures 41, includingevenly spaced apertures on lateral side 14 of lace region 16 extendingfrom ankle opening 50 to forefoot region 11. Similarly, upper 20 mayinclude a symmetrical, evenly spaced group of lace apertures 41 onmedial side 14 of lace region 16. Lace 40 may be interwoven thoughapertures 41 in any suitable configuration.

Still referring to FIGS. 1-3, upper 20 includes regions or patterns ofprinted material 70. Consistent with an embodiment, printed material 70may be formed by direct 3D printing and curing of material onto upper 20in any desired pattern, shape, thickness, or coverage. Printing andcuring of printed material 70 will be described in greater detail below.As shown in FIGS. 1-3, printed material 70 is depicted in an exemplarymanner as a pattern of interconnected strips and loops of predeterminedthickness attached to various portions of upper 20 to provide structuralsupport and/or aesthetic improvements to footwear 10. Various portionsof printed material 70 may be interconnected, but may also not beinterconnected. Consistent with an embodiment, printed material 70 isadhered or otherwise bonded to upper 20, may be at least partiallyabsorbed into a surface of upper 20, and may be formed in one or morecontiguous or disjointed layers on upper 20. Each of these features willbe described in greater detail below.

Consistent with an embodiment, printed material 70 may be made of amaterial that includes an ink, a resin, an acrylic, a polymer, athermoplastic material, a thermosetting material, a light-curablematerial, or combinations thereof. Also consistent with an embodiment,printed material 70 may be formed from printing of one or more layers ina sequence of depositions of material to any desired thickness, and mayalso include a filler material to impart a strengthening or aestheticaspect to printed material 70. For example, the filler material may be apowdered material or dye designed to impart desired color or colorpatterns or transitions, metallic or plastic particles or shavings, orany other powdered mineral, metal, or plastic, and may customize thehardness, strength, or elasticity of printed 70 depending on desiredproperties. Filler material may be premixed with printed material 70prior to printing, or may be mixed with printed material 70 duringprinting onto upper 20. Consistent with an embodiment, printed material70 may thus be a composite material.

FIGS. 4 and 5 show a perspective cutaway view and exploded perspectivecutaway view, respectfully, of section 4 of footwear 10 shown in FIG. 3,including printed sole structure 30 comprising outsole 32, midsole 31,and optional sockliner 33. It will be appreciated that some illustratedportions of printed sole structure 30 may be optional, and certainportions may be omitted in some embodiments. Alternatively, solestructure 30 may optionally comprise additional printed layers. Forexample, sole structure 30 may additionally comprise one or more layersof material (not shown) printed in accordance with disclosedembodiments. Such materials may comprise, for example, one or moreprinted polyurethane layers to form an enclosed region of air or othergas or fluid in one or more regions of sole structure 30, thus providingan enclosed cushioning region (not shown) in footwear 10.

As shown in FIGS. 4 and 5, footwear 10 also includes upper 20 and tongue60, upper 20 being attached to printed sole structure 30 as previouslydescribed. Consistent with an embodiment, printed material 70 may beadhered or bonded on or in an exterior surface of upper 20. It will beappreciated that some illustrated elements of printed material 70 mayvary in appearance. Alternatively, other additional elements may beincluded. For example, printed material 70 may comprise one or moreadditional layers to constitute material of any desired thickness, whichwill be described in greater detail below.

A method for making an article of apparel or footwear may includeprovisions for direct 3D printing onto the article. Consistent with anembodiment, FIG. 6 shows an exemplary system 80 for 3D printing directlyonto a fabric upper, such as, for example, upper 20 and sole structure30 shown in any of FIGS. 1-5. System 80 may include 3D printer device81, computer/workstation 82, print server 83, and optional switchingdevice 84. 3D printer device 81, computer 82, print server 83, andswitching device 84 may be in communication and/or networked as shown inFIG. 6. One of ordinary skill in the art will recognize that portions ofsystem 80 may be omitted in some embodiments.

Still referring to FIG. 6, computer 82 may be in direct communicationwith 3D printer device 81 and print server 83 via switching device 84.For example, print server 83 may be in direct communication with 3Dprinter device 81 and switching device 84, and switching device 84 maylikewise be in direct communication with 3D printer device 81 and printserver 83. Print server 83 may include a second nontransitorycomputer-readable medium encoded with a second computer program productloadable into a memory of print server 83 and include second softwarecode portions for instructing 3D printer device 81 to print directlyonto upper 20 through a sequence of printing steps to produce a 3Dresult of printed material 70 from CAD representation 89 on computer 82.Consistent with an embodiment, one of ordinary skill will understandthat system 80 may require both computer 82 and print server 83, or mayrequire just one of computer 82 and print server 83.

Consistent with an embodiment, computer 82 may comprise a centralprocessing device 85, viewing interface 86 (e.g., a monitor or screen),input devices 87 and 88 (e.g., keyboard and mouse), and software fordesigning a computer-aided design (“CAD”) representation 89 of aprinting output designed for upper 20. The term “computer,” as usedthroughout the disclosure, means a single computer, the partialcomputing resources of a computer, or two or more computerscommunicating with each other. Computer 82 may thus include a firstnontransitory computer-readable medium in central processing device 85encoded with a first computer program product loadable into a memory ofcomputer 82 and include first software code portions for storing a 3Dpattern for printing directly onto upper 20. Consistent with anembodiment, computer 82 may be used to prepare a CAD representation 89for any desired printed pattern or chemistry for printed material 70 onupper 20.

As shown in FIG. 7, 3D printer device 81 comprises a tray 90 forreceiving upper 20 for printing. 3D printer device 81 also may compriseat least one printhead 92, printhead maneuverability assembly 94, andlid 96. Printing material to be ejected from at least one printhead 92may be stored or supplied in compartment 98. Consistent with anembodiment, FIG. 7 illustrates a completed pattern of printed material70 printed on upper 20, in accordance with exemplary CAD representation89 shown in FIG. 6, and implemented by print server 83 and/or computer82. Printhead 92 may also include, for example, a UV light producingmechanism for curing printed material 70 upon printing by printhead 92as printhead 92 is moved over upper 20 via printhead maneuverabilityassembly 94. Upon completion of printing onto upper 20, lid 96 may beopened and upper 20 may be removed from 3D printer device 81.

Contrary to what is known in the art, embodiments of the disclosedmethods do not require a hydrophobic or otherwise non-wetting surface onwhich to print. One of ordinary skill in the art will understand thatknown 3D printing systems require a hydrophobic sheet or release layeron a tray or substrate prior to printing/building of a 3D object. Such ahydrophobic sheet or release layer may be preexisting on the tray orsubstrate, or may be a printed hydrophobic material provided by the 3Dprinting system itself. In known 3D printing systems, the requiredhydrophobic sheet or release layer prevents wetting of printed materialonto the tray or substrate during printing/building of the 3D object andthus permits removal of the 3D object from the tray or substrate uponcompletion of printing. Consistent with an embodiment, however, 3Dprinter device 81 does not require a hydrophobic or otherwisenon-wetting surface on which to print, because 3D printing isaccomplished directly onto a material (e.g., upper 20) placed on tray90. Upper 20, if an exemplary fabric material, may also be hydrophilic.That is, wetting and adhering/bonding/curing of printed material 70 toupper 20 is desirable. After printing, upper 20 may be removed from tray90 with printed material 70 adhered/bonded/cured to upper 20, withoutconcern for adhesion of upper 20 or printed material 70 to tray 90.

Contrary to what is known in the art, embodiments of the disclosedmethods also do not require not require a perfectly or near-perfectlyflat substrate surface on which to print. One of ordinary skill in theart will understand that known 3D printing systems require a perfectlyor near-perfectly flat substrate surface on which to print in order toallow the systems to print/build 3D objects on a planar surface.Consistent with an embodiment, however, upper 20—even if laidsubstantially flat inside 3D printer device 81 on tray 90—may still havean uneven surface due to either the knit or weave of its fabric, orirregular surface topology in general due to the need for subsequentworking and assembly steps. Consistent with an embodiment, 3D printerdevice 81 may account for surface irregularities of upper 20, andcompensate for any such irregularities by adjusting one or more of thedistance between printhead 92 and upper 20, and thesize/rate/distribution of material ejected from printhead 92 duringprinting onto upper 20. That is, printing may occur directly onto asurface of upper 20, such that upper 20 may be subsequently removed from3D printer device 81 without any concern for surface irregularities inupper 20.

For example, with reference to FIGS. 8 and 9, known 3D printingtechniques require printing on flat substrate 100 having a release layer102 placed/formed/printed thereon. To prevent printed object 104 fromadhering to substrate 100, release layer 102 is interspersedtherebetween. Release layer 102 could be a wax paper, for example, or alayer of hydrophobic printed material to facilitate removal of printedobject 104 from substrate 100. As shown in FIG. 9, removal of printedmaterial 104 may thus be accomplished by removing release layer 102 fromsubstrate 100 as shown by motion 106, followed by removal of printedmaterial 104 from release layer 102 as shown by motion 108. Thus, known3D printing techniques require both a flat surface on which to print,and a release layer to prevent adhesion of the printed material to thesubstrate after printing is complete.

Contrary to what is known in the art, FIGS. 10 and 11, and likewise 12and 13, illustrate a portion of a 3D printing technique consistent withan embodiment. For example, FIGS. 10 and 11 show a cross sectional viewof upper 20 placed on tray 90. Upper 20 is depicted as comprisingthreads 22, which may be placed in different directions, althoughthreads 22 could be configured in any manner, such as any density orthickness, to form upper 20. Printed material 70 may comprise one ormore layers of material sequentially printed onto upper 20. Consistentwith an embodiment, printed material 70 may be at least partiallyabsorbed into a surface region 110 of upper 20 after printing and priorto curing. Partial absorption in surface region 110 of printed material70 may aid in adhesion/bonding of printed material 70 to upper 20. FIGS.12 and 13 likewise illustrate a perspective view of upper 20 placed ontray 90 and having printed material 70 printed thereon.

As shown in FIGS. 11 and 13, and consistent with an embodiment, removalof upper 20 containing printed material 70 may be accomplished by simplylifting upper 20 away from tray 90, as shown by motion 115. Becauseprinted material 70 is printed/deposited onto upper 20, and may be atleast partially absorbed into a surface region 110, upper 20 may thusserve as a “substrate” such that there is no need for a release layerinterspersed between upper 20 and printed material 70, or between tray90 and upper 20. That is, wetting and adhering/bonding/curing of printedmaterial 70 to upper 20 is desirable and accomplished. After printing,upper 20 may be removed from tray 90 with printed material 70adhered/bonded/cured to upper 20, and without concern for adhesion ofupper 20 or printed material 70 to tray 90. Consistent with anembodiment, a release layer may be optionally used, however unlikely,for example if upper 20 is so thin or contains a particularly lowdensity of threads 22 such that portions of printed material 70 mightpass between individual threads 22 of upper 20 and directly contact tray90.

Consistent with an embodiment, FIGS. 14-17 illustrate cross sectionalviews of a printing sequence of multiple 3D layers of printed material70 on upper 20. For example, FIG. 14 illustrates first layer 71 ofprinted material 70 deposited onto upper 20. Printed material 70 may beejected or otherwise emitted from printhead 120 via nozzle 122 in theform of droplets 124. One of ordinary skill in the art will recognizethat the form of droplets 124 may vary depending on the actual materialejected or otherwise emitted from nozzle 122. Droplets 124 may thus beany viscosity liquid material, or even a semi-solid material. Consistentwith an embodiment, droplets 124 may be any desired material or phase ofmaterial suitable for use in 3D printing system 80.

Still referring to FIG. 14, in some embodiments, first layer 71 may becured by UV light 126, however, in other embodiments, first layer 71 maybe deposited without the need to cure the deposited material. Dependingon the material used for printing of printed material 70, the materialmay be deposited in a liquid, semi-liquid, or otherwise gel-like orviscous phase. The material may then be solidified, at least partially,or cured, for various reasons, or to achieve desired properties, forexample, to enhance durability, adhesion, or bonding of printed material70 to upper 20. FIGS. 14-17 thus illustrate UV light 126 as an exemplarycuring agent for use after deposition of printed material 70. One ofordinary skill in the art will understand that UV light 126 may beactivated/applied either immediately after deposition of first layer 71,or at any desired time thereafter, depending on the nature of thedesired patterns/chemistry/thickness of printed material 70. Forsimplicity, exemplary FIGS. 14-17 illustrate UV light 126 applied tocure printed material 70 after deposition of each layer. Depending onthe material used for printing of printed material 70, one of ordinaryskill in the art will recognize that curing of printed material 70 maybe optional.

Still referring to FIG. 14, and consistent with an embodiment, printedmaterial 70 may be at least partially absorbed into a surface region 110of upper 20 prior to curing. For example, printed material 70 may beallowed to absorb into upper 20 for a predetermined amount of time afterdeposition and prior to curing with UV light 126. One of ordinary skillin the art will understand that such a predetermined amount of time willvary depending on the material used for printed material 70, as anabsorption rate may be affected by the wettability or permeability ofupper 20 to the deposited material, the viscosity or temperature of thematerial during printing, and the pressure or speed at which thematerial is ejected from printhead 92 onto upper 20. Consistent with anembodiment, therefore, such a predetermined amount of time afterdeposition and prior to optional curing with UV light 126 may beessentially immediately after deposition, or may be contemplated secondsor minutes thereafter.

Consistent with an embodiment, FIG. 15 illustrates second layer 72 ofprinted material 70 deposited onto layer 71, and cured by UV light 126.Second layer 72 may or may not be partially absorbed into a portion offirst layer 71 prior to curing. Consistent with an embodiment, secondlayer 72 (and any subsequent layers) need not be deposited solely on theimmediately underlying layer. One of ordinary skill in the art willunderstand that variations in printing patterns/thicknesses layers arecontemplated. For example, second layer 72 may be deposited on anydesired portion of upper 20, which may include partial or completecoverage of layer 71, or may include no coverage of layer 71. Forexample, if second layer 72 is partially deposited on layer 71 andpartially deposited on upper 20, second layer 72 may or may not bepartially absorbed into a portion of first layer 71 and a portion ofupper 20 prior to optional curing.

Consistent with an embodiment, FIG. 16 illustrates a third layer 73 ofprinted material 70 deposited onto layer 72, and optionally cured by UVlight 126. Third layer 73 may or may not be partially absorbed into atleast a portion of second layer 72, at least a portion of first layer71, and/or at least a portion of upper 20 if so printed, prior tocuring. FIG. 17 likewise illustrates a fourth layer 74 of printedmaterial 70 deposited onto layer 73, and optionally cured by UV light126. Fourth layer 74 may or may not be partially absorbed into at leasta portion of third layer 73, at least a portion of second layer 72, atleast a portion of first layer 71, and/or at least a portion of upper 20if so printed, prior to optional curing. Consistent with an embodiment,any number of layers may be printed to form printed material 70. Alsoconsistent with an embodiment, upper 20 may be removed from tray 90 uponcompletion of printing, as shown in FIG. 13.

One of ordinary skill in the art will recognize that the printed layersforming printed material 70 may originate with different materials,colors, chemistries, optional fillers, etc., in order to fully customizethe desired properties of upper 20. Printed material may also compriselayers having gradients of colors blended amongst the layers, or maycomprise gradients of elasticity due to variations in material ejectedfrom printhead 92 during printing of printed material 70. For example,printed material 70 may comprise layers of low elasticity printedmaterial alternated or in conjunction with layers of high elasticitymaterial. Consistent with an embodiment, exemplary moduli of elasticityfor printed material 70 may range from about 10 MPa to about 4,000 MPa.Consistent with an embodiment, exemplary flexural strength for printedmaterial 70 may range from about 35 MPa to about 300 MPa. Consistentwith an embodiment, exemplary flexural moduli for printed material 70may range from about 1,200 MPa to about 12,000 MPa. And, consistent withan embodiment, exemplary tensile strength for printed material 70 mayrange from about 0.5 MPa to about 150 MPa.

One of ordinary skill in the art will also recognize that the printedlayers forming printed material 70 may comprise layers of materialhaving at least a first color alternated or in conjunction with layershaving at least a second color. For example, printed material 70 may bedesigned to impart high strength and low elasticity in heel region 13,while maintaining high elasticity and flexibility in toe region 11, andsuch properties may be accomplished by varying the properties of printedmaterial 70 through printing of different combinations of materials andlayers in any desired manner on any surface of upper 20.

Consistent with an embodiment, FIG. 18 illustrates an overhead view ofupper 20 placed on tray 90 prior to 3D printing in system 80, and FIG.19 illustrates a cross sectional view of the indicated portion of FIG.14 showing upper 20 on tray 90. As shown in FIGS. 18 and 19, upper 20may be positioned substantially flat on tray 90 in 3D printer 81. Upper20 may further be positioned and aligned with fiduciary marks (notshown) to coordinate alignment with CAD representation 89 from computer82 to facilitate accurate printing.

Consistent with an embodiment, FIG. 20 illustrates an overhead view ofupper 20 placed on tray 90 after 3D printing in system 80, and FIG. 21illustrates a cross sectional view of the indicated portion of FIG. 20showing exemplary printed material 70 on upper 20. As shown in FIGS. 20and 21, printed material 70 is deposited on upper 20 in any desiredpattern or number of layers, in accordance with a desired CADrepresentation 89 from computer 82 in implementation of system 80 shownin FIG. 6. It will be recognized that printed material 70, shown in FIG.21, may appear to be one continuous deposit of material as shown,although it may actually comprise multiple layers of sequentiallyprinted material to form a desired printed pattern resulting in printedmaterial 70 as shown.

Similarly, and consistent with an embodiment, FIG. 22 illustrates anelevated view of an article of footwear after printing of a 3D solestructure 30 onto a bottom surface of upper 20. As shown in FIG. 22,after printing onto upper 20, upper 20 may be further formed ormanipulated and then placed on holder 91, where it may then be inserted,placed, or mounted in or on tray 90 prior to 3D printing in system 80.Printed sole material 79 is then deposited on upper 20 in any desiredpattern or number of layers, in accordance with a desired CADrepresentation 89 from computer 82 in implementation of system 80 shownin FIG. 6. It will be recognized that printed sole material 79, shown inFIG. 22 and described in greater detail below with respect to FIGS.26-39, may comprise multiple layers of sequentially printed material toform a desired printed pattern resulting in printed sole material 79 asshown.

For example, consistent with an embodiment, FIG. 23 illustrates anexemplary printing job 300 using system 80 to produce printed material70 as shown and described with reference to FIGS. 20 and 21. Printingjob 300 in FIG. 23 will be further described consistent with exemplaryprocess flow 400 shown in FIG. 24.

FIG. 24 shows an exemplary process 400 for 3D printing onto upper 20,consistent with an embodiment. It will be appreciated that some or allsteps in the process may be completed by a footwear, apparel, orequipment manufacturer or proprietor. In other cases, some steps couldbe accomplished by a manufacturer and other steps could be accomplishedby another party including another manufacturer, proprietor, retailer,or any other entity. In some cases, one or more of the steps may beoptional. In other cases, some steps may be completed in a differentorder.

As shown in FIG. 24, exemplary process 400 for 3D printing onto upper 20begins with step 402. In step 402, computer 82 may be used to design aprint pattern and form CAD representation 89 shown in FIG. 22. CADrepresentation 89 may be any desired printing job on any surface, suchas upper 20. One of ordinary skill in the art will recognize that CADrepresentation 89, while shown as a design for printing material ontoupper 20, may also be used to prepare a design for printing a solestructure onto a bottom surface of upper 20.

In step 404, 3D printing is accomplished onto at least a first surfaceof upper 20, followed by printing of a sole structure onto at least asecond surface of upper 20 in step 406. Finally, in step 408, inspectionor quality control is performed after completion of 3D printing.

As shown in FIG. 25, step 404 is explained in greater detail. In step2502, computer 82 may be used to design a print pattern and form CADrepresentation 89 in a design for printing a sole structure onto abottom surface of upper 20.

In step 2504, CAD representation 89 may be provided to print server 83via optional switching device 84. Print server 83 may process CADrepresentation 89 into any number of slices 310 designed to accomplish3D printing of print material 70 to any desired pattern or thickness in3D printer 81. One of ordinary skill in the art will recognize thatslices 310 may be representations designed to correspond to actualprinted layers of material forming printed material 70, such as, forexample, layers 71-74 shown and described with reference to FIGS. 14-17.

In step 2506, a fabric material such as upper 20 may be inserted in 3Dprinter device 81 on tray 90, as shown in FIG. 7. In step 2508, fabricmaterial such as upper 20 may be positioned as described above withrespect to FIG. 18 to facilitate accurate printing of any desired CADrepresentation 89 and any number of slices 310.

In step 2510, 3D printer 81 executes printing onto fabric material suchas upper 20, using slices 310 provided by computer 82 and print server83 as guides for printing and curing multiple layers of material to formprinted material 70, such as those shown in FIGS. 10-13. As discussedabove, printing may include printing a resin, acrylic, or ink materialonto a fabric, where the material is adhered/bonded to the fabric andwhere the material does not generally delaminate when flexed, rolled,worked, or subject to additional assembly processes/steps. Consistentwith step 2510, printed material 70 may be an ink, a resin, an acrylic,a polymer, a thermoplastic material, a thermosetting material, alight-curable material, or combinations thereof. Printed material 70 mayalso include a filler material (not shown) to impart a strengthening oraesthetic aspect to printed material 70 in one or more layers printedusing slices 310. For example, the filler material incorporated inprinted material 70 may be a powdered material or dye designed to impartdesired color or color patterns or transitions, metallic or plasticparticles or shavings, or any other powdered mineral, metal, or plastic.Consistent with an embodiment, printed material 70 printed in step 2510may thus be a composite material.

In step 2512, progress of printing in 3D printer 81 may be periodicallyevaluated. For example, one may evaluate the progress of printing afterseveral layers of material are printed and cured, as shown, for example,in FIGS. 14-17.

In step 2514, if desired printing is not complete, or if adjustments aredesired during printing, fabric material such as upper 20 may berepositioned on tray 90 and realigned to facilitate printing of desiredCAD representation 89 by proceeding back to step 2510.

In step 2516, if desired printing is complete, fabric material such asupper 20 may be inspected and removed from 3D printer 81 by liftingupper 20 off of tray 90 by motion 115 shown in FIGS. 11 and 13. In step2516, desired printing may appear as shown in FIGS. 20 and 21, whereprinted material 70 if formed to any desired pattern and thickness, andmay or may not be partially absorbed into a portion 110 of the surfaceof upper 20.

As shown in FIG. 26, step 406 is explained in greater detail. In step2602, upper 20 may be formed into a secondary shape as described laterwith respect to FIGS. 27-31 in preparation for printing sole structure30 onto article of footwear 10. In step 2604, formed upper 20 may beplaced onto holder 91 in preparation for printing sole structure 30 ontoarticle of footwear 10 as described later with respect to FIGS. 32 and33.

In step 2606, holder 91 holding formed upper 20 may be inserted in 3Dprinter device 81 on tray 90, similar to what is shown in FIG. 7, and asshown in a pre-printing stage in FIGS. 32 and 33, and in a post-printingstage of sole structure 30 in FIG. 22. In step 2608, holder 91 holdingupper 20 may be positioned as described above with respect to FIG. 18 tofacilitate accurate printing of any desired CAD representation 89 andany number of slices 310.

In step 2610, 3D printer 81 executes printing of a sole structure onto abottom surface of formed upper 20, using slices 310 provided by computer82 and print server 83 as guides for printing and curing multiple layersof material, such as those shown in FIGS. 10-13. As discussed above,printing may include printing a resin, acrylic, or ink material onto afabric, where the material is adhered/bonded to the fabric and where thematerial does not generally delaminate when flexed, rolled, worked, orsubject to additional assembly processes/steps. Consistent with anembodiment, the printed sole structure may also include a fillermaterial (not shown) to impart a strengthening or aesthetic aspect tothe sole structure in one or more layers printed using slices 310. Forexample, the filler material may be a powdered material or dye designedto impart desired color or color patterns or transitions, metallic orplastic particles or shavings, or any other powdered mineral, metal, orplastic. Consistent with an embodiment, the sole structure printed instep 2610 may thus be a composite material.

In step 2612, progress of printing in 3D printer 81 may be periodicallyevaluated. For example, one may evaluate the progress of printing afterseveral layers of material are printed and cured, as shown, for example,in FIGS. 30-33.

In step 2614, if desired printing is not complete, or if adjustments aredesired during printing, holder 91 holding upper 20 may be repositionedon tray 90 and realigned, or printing materials for use in 3D printingmay be changed, to facilitate printing of desired CAD representation 89by proceeding back to step 2610.

In step 2616, if desired printing is complete, printed sole structure 79may be inspected and holder 91 removed from 3D printer 81. In step 2616,desired printing may appear in any desired shape, pattern, or thickness,for example, as shown in FIG. 39 or 45, and may or may not be partiallyabsorbed into a portion of the bottom surface of upper 20.

Consistent with an embodiment, FIG. 27 illustrates an approximately planview of upper 20 including tongue 60 and lace apertures 41 laidsubstantially flat after printing of printed material 70 and prior toprinting of sole structure 30 on footwear 10 shown in FIGS. 1-5. Asshown in FIG. 27, upper 20 may contain one or more regions of fabric 23,which may or may not contain printed material 70, in order to facilitateforming of upper 20 for printing of sole structure 30.

For example, FIG. 28 illustrates upper 20 including tongue 60, laceapertures 41, printed material 70, and sockliner 33 during a portion ofan exemplary assembly process of manufacturing footwear 10. As shown inFIG. 28, upper 20 may be formed and shaped after printing of printedmaterial 70, in preparation for mating with and attachment to sockliner33. Further, as shown in FIG. 29, and consistent with an embodiment,upper 20 is then connected with Strobel-stitch 34 to sockliner 33 tocomplete formation of upper 20 into a secondary shape. Upper 20 andsockliner 33 may then be further manipulated to present a bottom surfaceof sockliner 33 for additional printing steps of sole materials as shownin FIG. 32, and as further described below.

Also for example, FIG. 30 illustrates upper 20 including tongue 60, laceapertures 41, printed material 70, and fabric 23 during a portion of anexemplary assembly process of manufacturing footwear 10, similar toFIGS. 27 and 28. As shown in FIG. 30, upper 20 may be formed and shapedafter printing, in preparation for printing of sole structure 30. Asshown in FIG. 30, fabric 23 may surround the region of upper 20containing printed material 70, and be part of upper 20. Further, asshown in FIG. 31, and consistent with an embodiment, upper 20, includingfabric 23, may be formed and shaped after printing onto upper 20, suchthat regions of fabric 23 are subsequently folded underneath upper 20and connected with line stitch 35 to complete formation of upper 20 intoa secondary shape. Upper 20 may then be further manipulated to present abottom surface for additional printing steps of sole materials as shownin FIG. 33, as further described below.

It will be appreciated that some illustrated elements of assembly offootwear 10 may vary or not be shown in the interest of simplifyingillustrations throughout this disclosure. For example, a last may or maynot be used to hold upper 20 in tray 90 shown in FIGS. 32 and 33.Alternatively, other additional elements or assembly steps may beincluded. For example, upper 20 may be joined to sockliner 33 usingthermoforming applications, such as polymer heat seal seam tapes asdisclosed in U.S. Pat. No. 8,028,440, which is incorporated herein byreference. Also for example, upper 20 may be joined to sockliner 33using one or more vacuum forming methods, such as those disclosed inU.S. Pat. No. 8,162,022 and in related and allowed U.S. patentapplication Ser. No. 13/352,717, both of which are also incorporatedherein by reference.

Consistent with an embodiment, FIGS. 34-37 illustrate cross sectionalviews of a printing sequence of multiple 3D layers of printed solematerial 79 on a bottom surface upper 20 to form sole structure 30. Forexample, FIG. 34 illustrates first layer 75 of printed sole material 79deposited onto upper 20. As described above with respect to FIGS. 14-17,printed sole material 79 may be ejected or otherwise emitted fromprinthead 120 via nozzle 122 in the form of droplets 124. One ofordinary skill in the art will recognize that the form of droplets 124may vary depending on the actual material ejected or otherwise emittedfrom nozzle 122. Droplets 124 may thus be any viscosity liquid material,or even a semi-solid material. Consistent with an embodiment, droplets124 may be any desired material or phase of material suitable for use in3D printing system 80.

Still referring to FIG. 34, in some embodiments, first layer 75 may becured by UV light 126, however, in other embodiments, first layer 75 maybe deposited without the need to cure the deposited material. Dependingon the material used for printing of printed sole material 79, thematerial may be deposited in a liquid, semi-liquid, or otherwisegel-like or viscous phase. The material may then be solidified, at leastpartially, or cured, for various reasons, or to achieve desiredproperties, for example, to enhance durability, adhesion, or bonding ofprinted sole material 79 to upper 20. FIGS. 34-37 thus illustrate UVlight 126 as an exemplary curing agent for use after deposition ofprinted sole material 79. One of ordinary skill in the art willunderstand that UV light 126 may be activated/applied either immediatelyafter deposition of first layer 75, or at any desired time thereafter,depending on the nature of the desired patterns/chemistry/thickness ofprinted sole material 79. For simplicity, exemplary FIGS. 34-37illustrate UV light 126 applied to cure printed sole material 79 afterdeposition of each layer. Depending on the material used for printing ofprinted sole material 79, one of ordinary skill in the art willrecognize that curing of printed sole material 79 may be optional.

Still referring to FIG. 34, and consistent with an embodiment, printedsole material 79 may be at least partially absorbed into a surfaceregion 210 of threads 22 prior to curing. For example, printed solematerial 79 may be allowed to absorb into threads 22 for a predeterminedamount of time after deposition and prior to curing with UV light 126.One of ordinary skill in the art will understand that such apredetermined amount of time will vary depending on the material usedfor printed sole material 79, as an absorption rate may be affected bythe wettability or permeability of threads 22 to the deposited material,the viscosity or temperature of the material during printing, and thepressure or speed at which the material is ejected from printhead 92onto threads 22. Consistent with an embodiment, therefore, such apredetermined amount of time after deposition and prior to optionalcuring with UV light 126 may be essentially immediately afterdeposition, or may be contemplated seconds or minutes thereafter.

Consistent with an embodiment, FIG. 35 illustrates second layer 76 ofprinted sole material 79 deposited onto layer 71, and cured by UV light126. Second layer 76 may or may not be partially absorbed into a portionof first layer 75 prior to curing. Consistent with an embodiment, secondlayer 76 (and any subsequent layers) need not be deposited solely on theimmediately underlying layer. One of ordinary skill in the art willunderstand that variations in printing patterns/thicknesses layers arecontemplated. For example, second layer 76 may be deposited on anydesired portion of upper 20, which may include partial or completecoverage of layer 75, or may include no coverage of layer 75. Forexample, if second layer 76 is partially deposited on layer 75 andpartially deposited on upper 20, second layer 76 may or may not bepartially absorbed into a portion of first layer 75 and a portion ofupper 20 prior to optional curing.

Consistent with an embodiment, FIG. 36 illustrates a third layer 77 ofprinted sole material 79 deposited onto layer 76, and optionally curedby UV light 126. Third layer 77 may or may not be partially absorbedinto at least a portion of second layer 76, at least a portion of firstlayer 75, and/or at least a portion of upper 20 if so printed, prior tocuring. FIG. 37 likewise illustrates a fourth layer 78 of printed solematerial 79 deposited onto layer 77, and optionally cured by UV light126. Fourth layer 78 may or may not be partially absorbed into at leasta portion of third layer 77, at least a portion of second layer 76, atleast a portion of first layer 75, and/or at least a portion of upper 20if so printed, prior to optional curing. Consistent with an embodiment,any number of layers may be printed to form printed sole material 79.Also consistent with an embodiment, upper 20 may be removed from tray 90upon completion of printing.

One of ordinary skill in the art will recognize that the printed layersforming printed sole material 79 may originate with different materials,colors, chemistries, optional fillers, etc., in order to fully customizethe desired properties of sole structure 30. Printed sole material 79may also comprise layers having gradients of colors blended amongst thelayers, or may comprise gradients of elasticity due to variations inmaterial ejected from printhead 92 during printing of printed solematerial 79. For example, printed sole material 79 may comprise layersof low elasticity printed material alternated or in conjunction withlayers of high elasticity material. Consistent with an embodiment,exemplary moduli of elasticity for printed sole material 79 may rangefrom about 10 MPa to about 4,000 MPa. Consistent with an embodiment,exemplary flexural strength for printed sole material 79 may range fromabout 35 MPa to about 300 MPa. Consistent with an embodiment, exemplaryflexural moduli for printed sole material 79 may range from about 1,200MPa to about 12,000 MPa. And, consistent with an embodiment, exemplarytensile strength for printed sole material 79 may range from about 0.5MPa to about 150 MPa.

One of ordinary skill in the art will also recognize that the printedlayers forming printed sole material 79 may comprise layers of materialhaving at least a first color alternated or in conjunction with layershaving at least a second color. For example, printed sole material 79may be designed to impart high strength and low elasticity in heelregion 13 of sole structure 30, while maintaining high elasticity andflexibility in toe region 11 of sole structure 30, and such propertiesmay be accomplished by varying the properties of printed sole material79 through printing of different combinations of materials and layers inany desired manner on any surface of upper 20.

For example, FIG. 38 illustrates a perspective view of a portion ofprinted sole material 79, showing threads 22 curved when upper 20 isformed into a secondary shape for 3D printing of sole structure 30.Consistent with an embodiment, as described in the examples above,variations in first printed layer 75, second printed layer 76, thirdprinted layer 77, and fourth printed layer 78 are shown in printed solematerial 79. Exemplary variations shown in FIG. 38 illustratecombinations of raised and recessed features as well as variedthicknesses in printed sole material 79. Such variations may be used toenhance any desired property of sole structure 30, such as, for example,increasing grip of sole structure 30 to the ground when footwear 10 isworn.

Consistent with an embodiment, FIG. 39 illustrates a perspective view offootwear 10 showing sole structure 30 after printing an exemplaryarrangement/pattern of printed sole material 79 described above withrespect to FIGS. 34-37. As shown in FIG. 39, several layers of printedsole material 79 are shown, including exemplary first layer 3402,exemplary second layer 3404, exemplary third layer 3406, and exemplaryfourth layer 3408. Consistent with an embodiment, first layer 3402,second layer 3404, third layer 3406, and fourth layer 3408 maycorrespond to first layer 75, second layer 76, third layer 77, andfourth layer 78, respectively, as shown in and described with respect toFIGS. 34-37. One of ordinary skill in the art will recognize, however,that these layers do not have to correspond as such.

Further, exemplary variations in printed sole material 79 areillustrated in FIG. 39 in the form of exemplary raised features 3410 andexemplary recessed features 3412. Consistent with an embodiment, raisedfeatures 3410 and recessed features 3412 may correspond to features inthird layer 77 and fourth layer 78 as shown in the perspective view ofFIG. 38. One of ordinary skill in the art will recognize, however, thatthese layers do not have to correspond as such. One of ordinary skill inthe art will also recognize that while an exemplary sole structure 30 isdepicted by printed sole material 79, any desired shape, pattern,thickness, construction, etc., may be formed by selectively printingprinted sole material 79 onto the bottom of upper 20. It will berecognized that printed sole material 79, shown in FIGS. 22, 39, and 45,for example, may appear to be one continuous deposit of material, or itmay actually comprise multiple layers of sequentially printed materialto form any desired printed pattern resulting in printed sole material79 as shown.

Consistent with an embodiment, FIG. 40 illustrates a perspective view ofupper 20 after 3D printing of alternative patterns and prior tocompletion of footwear assembly, similar to FIGS. 20 and 27. FIG. 40thus illustrates first printed material 510 and second printed material520 on upper 20, printed using system 80 and process 400. For reference,exemplary printing directions XY and Z are shown in FIG. 40. Consistentwith an embodiment, first printed material 510 and second printedmaterial 520 may be different materials. For example, first printedmaterial 510 may be a thin, abrasion-resistant material. Also, forexample, second printed material 520 may be a thicker, stiff materialdesigned to provide structural support to a portion of upper 20. Firstprinted material 510 and second printed material 520 may be disposed onany desired portion or portions of upper 20.

First printed material 510 and second printed material 520 may beprinted to upper 20 to impart customized properties such as increasedstrength, rigidity, support, flexibility, abrasion resistance, orvariations thereof based on desired properties for specific portions ofthe upper and the article of footwear as a whole. For example, FIGS.41-45 illustrate footwear 10 with first printed material 510 and secondprinted material 520 disposed on upper 20. Consistent with anembodiment, first printed material 510 and second printed material 520may be formed by direct 3D printing and curing of material onto upper 20in any desired pattern, shape, or coverage. Printing and curing of firstprinted material 510 and second printed material 520 may be performed inaccordance with exemplary system 80 and exemplary process 400. Likewise,as similarly discussed with respect to FIGS. 1-5, various portions offirst printed material 510 and second printed material 520 may beinterconnected, but may also not be interconnected. While first printedmaterial 510 and second printed material 520 are generally shown inFIGS. 40-45 in forefoot and heel regions, respectively, of upper 20, oneof ordinary skill in the art will recognize that first printed material510 and second printed material 520, or one or more additional printedmaterials (not shown), may also be printed in the midfoot region or anyother region of footwear 10. Consistent with an embodiment, firstprinted material 510 and second printed material 520 are adhered orotherwise bonded to upper 20, may be at least partially absorbed into asurface of upper 20, and may be formed in one or more contiguous ordisjointed layers on upper 20. After printing of first printed material510 and second printed material 520, upper 20 may be shaped for furtherprinting of sole materials as shown in the depictions in FIGS. 28-33.

As shown in the various views of footwear 10 in FIGS. 41-45, forexample, footwear 10 may comprise first printed material 510 as one ormore abrasion resistant pads located in either or both of forefootregion 11 and midfoot region 12, and may be useful for protectingfootwear 10, for example, while engaging in soccer. Likewise, secondprinted material 520 may be a strengthening rigid material customized toprovide strength and support to heel region 13 of footwear 10.Consistent with an embodiment, moreover, first printed material 510 maybe thinner than second printed material 520. One of ordinary skill inthe art will recognize that the thickness of first printed material 510and second printed material 520 may differ or be the same, however,depending on the desired application or use of footwear 10.

FIGS. 41-45 also illustrate alternative patterns for features on solestructure 30, for example, as cleated tread patterns for use in certainathletic shoes. For example, FIGS. 41-45 variously illustrate treadpatterns 3702 printed on layer 3704, as well as structure 3706,structure 3708, and structure 3710 to form a multilayered complex cleatstructure 3712 illustrated in FIGS. 43 and 45. One of ordinary skill inthe art will recognize that the layers comprising complex cleatstructure 3712 may be printed in any desired pattern, shape, orthickness through any number of separately, sequentially, continuously,or contiguously printed layers using any desired printing materialdescribed in this disclosure or otherwise suitable for use in 3Dprinting systems.

One of ordinary skill in the art will recognize that printed materialsconsistent with an embodiment may have a structural aspect, a visual oraesthetic aspect, or both. For example, printed materials consistentwith an embodiment may be a visual or decorative indicia, logo, graphic,or reflector in the midfoot region or any other regions of footwear 10.Likewise, for example, printed materials consistent with an embodimentmay be a structural material, to impart strength, abrasion resistance,protection, or stiffness to one or more regions of footwear 10.Consistent with an embodiment, printed materials may have a firstcharacteristic for a first portion of footwear 10, and a second, third,etc., or other additional characteristics for one or more additionalregions of footwear 10.

Thus, for example, as shown in FIGS. 41-45 and generally in the otherfigures, and consistent with an embodiment, footwear 10 may befabricated by designing at least a first three dimensional pattern and asecond three dimensional pattern (such as one or more CADrepresentations 89 shown in FIG. 6) for printing onto upper 20;providing the at least first and second three dimensional patterns toprint server 83; positioning at least a first portion of upper 20 ontray 90 in 3D printer device 81 of system 80, the first portion beingpositioned substantially flat on tray 90; aligning the first portion ofupper 20 with the first pattern (as shown, for example, in FIG. 18);printing at least one layer of first printed material 510 having a firstmaterial property directly onto the first portion of upper 20 using thedesigned first pattern; allowing the at least one layer of first printedmaterial 510 to at least partially absorb into a first portion of asurface of upper 20; curing the at least one layer of first printedmaterial 510; positioning at least a second portion of upper 20 on tray90, the second portion being positioned substantially flat on tray 90;aligning the second portion of the upper with the second pattern (assimilarly shown, for example, in FIG. 18); printing at least one layerof second printed material 520 having a second material propertydirectly onto the second portion of upper 20 using the designed secondpattern; allowing the at least one layer of second printed material 520to at least partially absorb into a second portion of the surface ofupper 20; curing the at least one layer of second printed material 520;removing upper 20 from 3D printer device 81; and assembling footwear 10using the printed upper and at least one footwear component chosen fromsock liner 33, midsole 31, and outsole 32 (as similarly shown, forexample, in FIGS. 5, 28, and 29). Moreover, one of ordinary skill in theart will recognize that features, components, or entire structures ofmidsole 31 and outsole 32 may be printed consistent with an embodiment,as shown for example in step 406 of FIG. 24, in FIG. 26, and in FIGS.34-39 and 45.

One of ordinary skill in the art will recognize that the systems andmethods described throughout this disclosure can be used to 3D print anydesired patterns, layers, or materials directly onto a fabric material,which allows building of a structure on the fabric for use in apparelapplications.

While various embodiments have been described, the description isintended to be exemplary, rather than limiting, and it will be apparentto those of ordinary skill in the art that many more embodiments andimplementations are possible that are within the scope of thedisclosure. It is intended that all such additional systems, methods,features and advantages be included within this description and thissummary, be within the scope of the disclosure, and be protected by thefollowing claims.

What is claimed is:
 1. A method of three-dimensional printing and assembly of an article of apparel, comprising: designing at least one first three-dimensional pattern and at least one second three-dimensional pattern for printing onto the article; positioning a first portion of the article on a tray in a three-dimensional printing system, the first portion being positioned substantially flat on the tray; printing at least one first three-dimensional material directly onto the first portion of the article using the designed at least one first three-dimensional pattern; curing the at least one first three-dimensional printed material; positioning a second portion of the article on the tray, the second portion being positioned substantially flat on the tray; printing at least one second three-dimensional material directly onto the second portion of the article using the designed at least one second three-dimensional pattern; curing the at least one second three-dimensional printed material; and removing the article from the three-dimensional printing system.
 2. The method according to claim 1, wherein the printing of the at least one first three-dimensional material and at least one second three-dimensional material onto the article each further comprises printing at least one layer of the material.
 3. The method according to claim 1, wherein the printing of the at least one first three-dimensional material and at least one second three-dimensional material each further comprises allowing the printed material to at least partially absorb into a surface of the article prior to the curing.
 4. The method according to claim 1, wherein the printing at least one first three-dimensional material onto the article further comprises: printing a first layer of the first material; allowing the first layer of first printed material to at least partially absorb into a first surface of the article; curing the first layer of the first printed material; printing at least one additional layer of the first material on the cured first layer of the first printed material; and curing the at least one additional layer of the first material.
 5. The method according to claim 1, wherein the printing at least one second three-dimensional material onto the article further comprises: printing a first layer of the second material; allowing the first layer of second printed material to at least partially absorb into a second surface of the article; curing the first layer of the second printed material; printing at least one additional layer of the second material on the cured first layer of the second printed material; and curing the at least one additional layer of the second material.
 6. The method according to claim 4, wherein the printed first layer of the first material has a first modulus of elasticity and the printed at least one additional layer of the first material has a second modulus of elasticity different than the first modulus.
 7. The method according to claim 5, wherein the printed first layer of the second material has a third modulus of elasticity and the printed at least one additional layer of the second material has a fourth modulus of elasticity different than the third modulus.
 8. The method according to claim 4, wherein the printed first layer of the first material has a first color and the printed at least one additional layer of the first material has a second color.
 9. The method according to claim 4, wherein the printed first layer of the second material has a third color and the printed at least one additional layer of the second material has a fourth color.
 10. The method according to claim 1, wherein the article of apparel is chosen from a textile, a natural fabric, a synthetic fabric, a knit, a woven material, a nonwoven material, a mesh, a leather, a synthetic leather, a polymer, a rubber, a foam, clothing, footwear, hats, caps, shirts, jerseys, jackets, socks, shorts, pants, undergarments, athletic support garments, gloves, wrist/arm bands, sleeves, and headbands.
 11. The method according to claim 1, wherein the portion of the article has at least one nonflat surface.
 12. The method according to claim 11, wherein the at least one nonflat surface is a substrate on which the printing occurs.
 13. The method according to claim 1, wherein the removing the article does not require a release layer disposed between the printed material and the tray.
 14. The method according to claim 1, wherein the printed at least one first three-dimensional material and the printed at least one second three-dimensional material are chosen from an ink, a resin, an acrylic, a polymer, a thermoplastic material, a thermosetting material, and a light-curable material.
 15. The method according to claim 1, wherein the printed at least one first three-dimensional material further comprises a first filler material, and the printed at least one second three-dimensional material further comprises a second filler material.
 16. The method according to claim 1, wherein the printed at least one first three-dimensional material and the printed at least one second three-dimensional material are adhered or bonded to the article.
 17. A method of fabricating an article of footwear, comprising: designing at least one first three-dimensional pattern for printing onto an upper and at least one second three-dimensional pattern for printing a sole; providing the at least one first three-dimensional pattern and the at least one second three-dimensional pattern to a print server; positioning at least a first portion of the upper on a tray in a three-dimensional printing system, the first portion of the upper being positioned substantially flat on the tray; aligning the first portion of the upper on the tray with the at least one first three-dimensional pattern; printing at least one first three-dimensional material directly onto the first portion of the upper using the designed at least one first three-dimensional pattern on the print server and the three-dimensional printing system; curing the at least one first three-dimensional printed material; removing the upper from the three-dimensional printing system; forming the upper into a secondary shape; placing the formed upper on a holder; positioning the holder on the tray, the holder being positioned on the tray to present a sole surface portion of the formed upper for printing the sole; aligning the holder on the tray with the at least one second three-dimensional pattern; printing the sole with at least one second three-dimensional material directly onto the sole surface portion of the formed upper using the designed at least one second three-dimensional pattern on the print server and the three-dimensional printing system; curing the at least one second three-dimensional printed material; removing the holder from the three-dimensional printing system; and removing the fabricated article of footwear from the holder.
 18. The method according to claim 17, wherein the printing of the at least one first three-dimensional material and at least one second three-dimensional material onto the article each further comprises printing at least one layer of the material.
 19. The method according to claim 17, wherein the printing of the at least one first three-dimensional material and at least one second three-dimensional material each further comprises allowing the printed material to at least partially absorb into a surface of the article prior to the curing.
 20. The method according to claim 17, wherein the printing onto the first portion of the upper further comprises: printing a first layer of the first material; allowing the first layer of first printed material to at least partially absorb into a first surface of the first portion of the upper; curing the first layer of the first printed material; printing at least one additional layer of the first material on the cured first layer of the first printed material; and curing the at least one additional layer of the first material.
 21. The method according to claim 20, wherein the printing the sole with at least one second three-dimensional material directly onto the sole surface portion of the formed upper further comprises: printing a first layer of the second material; allowing the first layer of second printed material to at least partially absorb into a the sole surface portion of the formed upper; curing the first layer of the second printed material; printing at least one additional layer of the second material on the cured first layer of the second printed material; and curing the at least one additional layer of the second material.
 22. The method according to claim 20, wherein the printed first layer of the first material has a first modulus of elasticity and the printed at least one additional layer of the first material has a second modulus of elasticity different than the first modulus.
 23. The method according to claim 21, wherein the printed first layer of the second material has a third modulus of elasticity and the printed at least one additional layer of the second material has a fourth modulus of elasticity different than the third modulus.
 24. The method according to claim 17, wherein the upper is chosen from a textile, a natural fabric, a synthetic fabric, a knit, a woven material, a nonwoven material, a mesh, a leather, a synthetic leather, a polymer, a rubber, and a foam.
 25. The method according to claim 17, wherein the portion of the upper has at least one nonflat surface.
 26. The method according to claim 25, wherein the at least one nonflat surface is a substrate on which the printing occurs.
 27. The method according to claim 17, wherein the removing the upper does not require a release layer disposed between the printed material and the tray.
 28. The method according to claim 17, wherein the printed at least one first three-dimensional material and the printed at least one second three-dimensional material are chosen from an ink, a resin, an acrylic, a polymer, a thermoplastic material, a thermosetting material, and a light-curable material.
 29. The method according to claim 17, wherein the printed at least one first three-dimensional material further comprises a first filler material, and the printed at least one second three-dimensional material further comprises a second filler material.
 30. The method according to claim 17, wherein the printed at least one first three-dimensional material and the printed at least one second three-dimensional material are adhered or bonded to the upper.
 31. The method according to claim 17, wherein the printing the at least one first three-dimensional material further comprises printing the material having a first gradient in modulus of elasticity within at least a region of the at least one first three-dimensional material.
 32. The method according to claim 17, wherein the printing the at least one second three-dimensional material further comprises printing the material having a second gradient in modulus of elasticity within at least a region of the at least one second three-dimensional material.
 33. The method according to claim 31, wherein the printing the at least one additional layer of the at least one first three-dimensional material further comprises printing multiple layers having varied moduli of elasticity as a function of depth or length of the printed material.
 34. The method according to claim 32, wherein the printing the at least one additional layer of the at least one second three-dimensional material further comprises printing multiple layers having varied moduli of elasticity as a function of depth or length of the printed material.
 35. A system for three-dimensional printing directly onto multiple surfaces of a fabric material, comprising: a first nontransitory computer-readable medium encoded with a first computer program product loadable into a first memory of a first computer and including first software code portions for storing a three-dimensional pattern for printing directly onto the upper; a print server; a switching device; and a three-dimensional printer device, wherein the print server is in direct communication with the three-dimensional printer device and the switching device, wherein the switching device is in direct communication with the three-dimensional printer device and the print server, wherein the first nontransitory computer readable medium is in direct communication with the switch, wherein the print server comprises a second nontransitory computer-readable medium encoded with a second computer program product loadable into a second memory of a second computer and including second software code portions for instructing the three-dimensional printing device to print directly onto the upper through a first sequence of printing steps and a second sequence of printing steps; wherein the three-dimensional printer device comprises a tray receiving at least a first surface of the fabric material and at least a second surface of the fabric material, at least one printing head for printing onto a first portion of the upper in the first sequence and onto a second portion of the upper in the second sequence, and at least one ultraviolet light for curing material printed onto the upper in the first and second sequences, and wherein the three-dimensional printing system does not require a substantially flat surface for printing. 